Process for single system electrocoagulation, magnetic, cavitation and flocculation (emc/f) treatment of water and wastewater

ABSTRACT

The current invention provides a novel process for the treatment and reclamation of drilling frac flowback and produced wastewater from the drilling industry. The wastewater is delivered to the EMC/F System from a frac tank or other reservoir. The wastewater is pumped into the system and is treated sequentially by passing through a mechanical hydrocavitation unit, an electromagnetic unit, an electrocoagulation unit and/or a hydrocyclone and a flocculation-sedimentation tank. Polishing of the final effluent is accomplished by passing the water through a mixed media tank.

RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.13/718,393 filed Dec. 18, 2012, which claims priority to U.S.Provisional Application No. 61/630,996, filed Dec. 23, 2011, and theentireties of both of which are hereby incorporated by reference for allpurposes.

FEDERALLY SPONSORED RESEARCH

Not Applicable.

JOINT RESEARCH AGREEMENTS

Not Applicable.

SEQUENCE LISTING

Not Applicable.

BACKGROUND OF THE INVENTION

The present invention relates to a process for the hydrocavitation,electromagnetic, electrocoagulation, hydrocyclone and flocculationtreatment of water and wastewater for purposes of reuse. Water coversmore than 70% of the earth's surface. But only 2.5% is freshwater.Two-thirds of that is locked up in ice caps and glaciers. Freshwateraccessible in lakes, rivers, and streams is just six-thousandths of onepercent of the world's total water. Climate change, drought, populationgrowth and pollution are stressing the planet's freshwater supply. Thiswill most likely mean that politicians, scientists and the generalpublic will have to make tough choices to adapt to a world where watercould outstrip fuel as the most prized commodity.

In March of 2012, it has been estimated that seven billion people wereliving on planet earth. They use nearly 30% of the world's totalaccessible and renewable supply of water. By 2025 this value may reach70%. Yet billions of these same people lack basic water supply services;estimates of 5 million people die each year from water-related diseases(e.g., typhoid and cholera). Water has also become a basis for regionaland international conflict.

A great deal of world-wide water use is non-consumptive which means thewater is returned to the environment. Usually this water is contaminatedwith an array of contaminants, whether it is used for agriculture,domestic consumption, or by industry. The world's water supply problemsare further complicated by increasing world population and pollution.

Wastewater treatment, recycling and reuse is an increasing necessity, asshortages, pollution and restriction on domestic users and commercialentities by government require that new, economically feasible andreadily adaptable technologies be developed for increasing supply.

Industry produces an array of pollutants or contaminants. These includedetergents, dyes, pharmaceuticals, petroleum products, oil, grease,heavy metals, biological and non-biological organic products, food andbeverage wastes. These wastewaters are most often discharged directly tothe sewer system, rather than treated and recycled for reuse byindustry. In many cases, such discharge is waste of a valuable resourcewhen one considers that technology is available to economically treatand recycle such wastewater streams.

In many parts of the world, especially developing countries, economicaland readily adaptable methods to treat water for domestic consumption isseverely lacking. Surface waters are often contaminated with untreatedhuman and animal waste, water borne disease organisms, heavy metals anddangerous organic products, including petroleum. Groundwater from wellsand boreholes is often contaminated with high concentrations of heavymetals, such as arsenic.

A wide range of wastewater treatment techniques are known. These includebiological processes for nitrification, denitrification and phosphorusremoval, as well as, a range of physico-chemical processes. Thephysico-chemical processes include filtration, ion exchange, chemicalprecipitation, chemical oxidation, carbon adsorption,electrocoagulation, ultrafiltration, reverse osmosis, electrodialysis,and photo-oxidation.

Treatment of wastewater by electrocoagulation (“EC”) has been practicedfor most of the twentieth century. It has achieved limited success inmost instances. The technology is increasingly being used in Europe forthe treatment of industrial wastewater containing heavy metals. In NorthAmerica the EC process has been employed to treat wastewater from thepulp and paper industry, effluents from the mining industry and metalsprocessing industry. This technology has been used to treat wastewatercontaining food stuffs, suspended particles, dyes, petroleum products,animal fats, landfill leachates, solutions of heavy metals, polishingcompounds, phosphorus, organic matter, pesticides and syntheticdetergents.

Electrocoagulation is the process that occurs within an electrolyticreactor or cell. The reactor is a cell containing an anode and acathode. When connected to an external power supply, the anode isoxidized and the cathode is passivated and reduction occurs, producinggases such as hydrogen. In practice, the electrodes are usually parallelmetal plates that serve as monopolar electrodes, which may be of thesame or different metal. The electrodes are attached to a DC powersupply that allows current and voltage adjustment. Under current flow tothe anode, an appropriate metal is oxidized and cations of the metal arereleased into the flowing wastewater. The anode is referred to as the“sacrificial electrode”, since it is ultimately consumed in thereaction. The ions produced in this reaction neutralize or destabilizecontaminants within the wastewater, which allows them to coagulate andprecipitate.

Known technology for such systems suffers from a number ofdisadvantages. These include:

-   -   Lack of Adaptability. Most systems are designed for single        purpose application and are fixed in their design for treating a        specific wastewater contaminant and/or treating at a specific        flow rate.    -   Lack of Efficiency. Most systems lack the capability to        efficiently treat a broad spectrum of wastewater contaminants.

Electricity has been used to treat and condition water since the late1800's. Significant improvements have been made in treatment technologyperiodically over the last century. Current knowledge development andimprovement in the water treatment art, demonstrated herein, has shownthat the EMC/F System which incorporates Electrocoagulation, Magnetic,Cavitation and Flocculation subsystems provides a significant advance inwater treatment technology. Significant research demonstration, testing,development and implementation show a novel and remarkably adaptabletechnology that can be appropriate for processing and treating variousdifficult-to-treat industrial wastewaters. Using the advanced EMC/F andtraditional separation technologies, the consumption of chemicals andenergy and associated costs for water treatment are significantlyreduced. Such characteristics would allow EMC/F to be classified as a“Green Technology”. In addition, the area dedicated to water treatment(plant footprint) for the EMC/F is smaller than for traditionaltechnologies. The ultimate objective in many instances is that thetreated water be clean enough to meet reuse standards in a facility oractivity which would further reduce cost and allow conservation oftreated water supplies and those of untreated supplies (rivers,reservoirs, and lakes).

History. Electrocoagulation and electroflocculation have been used bymany industries over the last century, principally mining, metalfinishing and fabrication. Energy companies developed high flow systemsto treat the wastewater from coal slurry pipelines (Westinghouse,General Electric). Metal finishing industries have used both flowthrough and batch systems for several decades. Enviro-Chem (Monsanto)modified the Russian membrane EC technology that separates the anolyte(flow from anode) and catholyte (flow from cathode) with a porousceramic membrane. Controlling the composition of the influents and theelectrical currents allows the production of “activated” water that canbe used to sterilize or treat wastewaters. The Germans were first tonote the ability of electrically processed water to carry energy andprovide treatment.

Electrical treatment of water has been practiced in several countriesfor many years. Eastern Europe, Germany and Argentina are notable forthe use of electrical energy for various purposes in water treatment.Electroflocculation is often used for removal of suspended solids fromsurface water supplies prior to chemical treatment to produce drinkingwater. On occasion, an induced current is used to remove microbes as afinal step in drinking water distribution. Electroflocculation is notwidely used as the primary treatment for either drinking water orwastewater.

A well known characteristic of electrical energy is magnetism. Manyboilers operate with electromagnets on the condensate return or feedwater lines. The energy is critical to the prevention of scaling fromcalcium and magnesium in the feed water. A magnetic field of a preciseforce around the pipes has been shown to reduce scaling by controllingthe speciation of these atoms as they precipitate from the water. Thepredominant species of calcium precipitated, post-magnetic treatment, isaragonite which does not form scale. Cavitation treatment, followed byMagnetic and Electrocoagulation treatments and finally Hydrocyclonetreatment to remove larger floc particles is a unique and novel conceptand process with all the above described technologies incorporated intoa single system, as described herein. This single system is furtherknown as the EMC/F technology.

As a technology with a long history and a well known capability,electrocoagulation has not been in the mainstream of water treatment.The high cost of replacing electrodes, the difficulties with productionof reliable, steady state power and the general misunderstanding ofelectrical treatment have hindered its acceptance. In addition, a numberof unscrupulous companies proliferated in the late 1990's promisingmiraculous treatments and not delivering quality equipment. Thetechnology appears to be very simple and it is easy to effect treatmenton bench scale or batch systems. Treatment with electricity is complexand many variables need to be addressed and accounted for to produce asuccessful full scale treatment unit.

In the following pages, the unique EMC/F technology will be described.This advanced system incorporates technologies with all of the physical,chemical and electrical concepts described. The EMC/F system utilizesthe DC electrical energy, cavitation, magnetic, electrocoagulation, andhydrocycloning to effect advanced wastewater treatment. This novel andunique technology process is a major step forward in the field andprovides the broadest applicability for the reduction in theconcentration of organic, inorganic, gaseous and biological contaminantsfound in wastewater and in water supplies.

Water is the universal solvent and has been the fundamental component ofindustrial and petrochemical development. Within the last half century,the realization of a finite water supply has developed. Regulatoryresponse has been the requirement for increasingly stringent treatmentof water before use or release. The properties that make water afundamental and important part of life also make it a difficult mediumto purify. Contaminants can be dissolved, colloidal, suspended,emulsified or any combinations thereof.

Water forms strong intermolecular bonds due to the polarity of themolecules. These bonds hold contaminants in the solution matrix or waterin the contaminant matrix. Energy must be externally applied in the formof magnetic, electrical and physical energy to destabilize such systemsand free the water and, simultaneously, allow contaminants to coagulateand flocculate from solution.

As a polarized solvent, charged water particles cause ions to dissociateand become part of the solution. For example, sodium chloride (NaCl) isa solid in the absence of water. However when dissolved in water itexists in solution in the dissociated ionic form: Na⁺¹ and Cl⁻¹.Attractive forces that hold materials in the water and cause watermolecules to align based on charge proximity also affect the physicalproperties of water. Water can absorb and hold significant amounts ofenergy with few changes in physical properties.

Water Treatment. Water treatment has changed little over the lastcentury. In general the technologies have been based on chemicaladditions to create insoluble products from contaminants, followed byfiltration to capture contaminants. Where organic components arepresent, biological, absorption or vapor extraction mechanisms have beenadded to the treatment process as appropriate. No new or dramaticapproach has been brought to the industry for forty years or more sincethe advent of Reverse Osmosis which employs high pressure filtration.Improvements in chemicals (e.g., particularly polymers) and geneticallyengineered or specifically cultured biological organisms are the mostcommon changes in process.

EMC/F technology offers a superior alternative to traditional watertreatment. The EMC/F system is differentiated from typicalelectrocoagulation and electroflocculation treatments. To address thisissue, it is critical to understand the nature of water treatment.

Contaminant chemicals in wastewater may be categorized into a number ofcategories. These categories are:

-   -   Organics—fat, oil, grease, hydrocarbons, solvents,        petrochemicals, food products, algae, bacteria and other        biological organisms,    -   Total Suspended Solids—non-dissolved inorganic materials in        colloidal suspension or dispersion; also known as TSS, and    -   Total Dissolved Solids—chemicals of a molecular or atomic level        dissolved in water and intimately associated with water        molecules; also known as TDS.

Organic materials are most commonly treated through biological(bacterial) degradation followed by settling and filtration. Air(oxygen) may be provided to enhance the biological activity. Nutrientsmay be added to optimize the metabolism and hence the decomposition ofthe contaminants. Ideally, the contaminants are converted to biomass,CO₂ and water. The biomass is removed in the filtration step withincorporated contaminants. Organics that are not a food source to theorganisms are removed from the water by mechanical means or throughconcentration on media that is further processed or stripped andconcentrated as vapor. Low concentrations of volatile organic carbonsmay be removed by using diffused aeration, activated carbon filters, UVlight and/or ozonation.

All processes identified require sizeable structures to accommodate flowor residency times. Current facilities represent significant capitalexpenditures and often receive discharges from industry that do not meetcurrent water quality standards. Such facilities are forced to pre-treattheir effluent and, in some cases, pay fees (surcharges) to dischargeover the legal standards.

Total Suspended Solids (“TSS”) are materials that can often be filteredfrom the wastewater. Filtration of large quantities of water is capitalintensive and time consuming. More efficient separation can be achievedby altering the dispersion forces through centrifugation. These systemsare complex and expensive. Chemicals are readily available that reactwith the suspended solids and/or the water to enhance the separation andremoval. Chemical treatment is the mainstay of the industry and thebasis for most treatment regulation. Additives function first to combinewith the suspended solids and neutralize electrical charges which thenallow larger particles to form that are easier to precipitate fromsolution. Chemicals, such as surface active agents, also are added toreduce the surface tension or polar attractiveness of the water allowingparticles to move with less resistance.

Chemical treatment has advanced through the creation of new products(polymers) that react more effectively with suspended solids. Somechemical treatments leave residual materials in the water. Overdosing isoften practiced to accommodate variations in the wastewater and can be acostly process.

Total Dissolved Solids (“TDS”) may be treated with chemical addition butmost often require additional sophisticated treatment methods after thesuspended solids are removed. Clarified wastewater can be treated withion exchange resins, mixed resin beds, microfiltration, ultrafiltration,electrodialysis or reverse osmosis. Resins are chemicals that that areused to attract and capture certain ions or molecules. Each resin is ionspecific, therefore a mixture of resins is needed to react with andremove the variety of ions found in wastewater. Resins eventually becomesaturated and must be treated to remove the captured ions. The resinwash is a concentrated wastewater that also must be treated.

Microfiltration, ultrafiltration and reverse osmosis (“RO”) aremechanical separation processes conducted under high pressure. Eachutilizes specially formulated membranes that allow smaller watermolecules to pass through while capturing the larger contaminantmolecules. Each process then produces a concentrate stream that must bemanaged and disposed.

The resins and membranes will produce the highest purity water, althoughat a high cost. Industrial and bottled water needs are met by somecombination of these techniques. De-mineralized and ultrapure water usedfor boiler feed, pharmaceutical production, and in chemical reactions,are produced by these techniques.

EMC/F system may be thought of as located between chemical/biologicaland de-mineralized/RO treatment systems. The technology is extremelyefficient (>95% removal) on suspended solids and some dispersed oils andgrease as well as most inorganic dissolved solids. EMC/F treatment isnot appropriate for “stand-alone” treatment of alcohols, sugars, amines,amides, pesticides, herbicides, chlorinated hydrocarbon solvents andcomplex surfactants.

EMC/F technology will enhance most treatment systems in use and can be apowerful tool in treatment systems under design. The versatility andconsistent response of EMC/F allows for a wide range of applications andless concern for wastewater consistency. Water treatment free fromdosage and flow limitations or monitoring allows more flexibility ofdesign and reduced costs of attention, maintenance, supplies, reagents,and down-time. High purity systems benefit from pretreatment by EMC/Ftechnology. Efficient removal of most contaminants would serve to extendresin or membrane life, reduce maintenance and downtime and increasecapacity of systems. Per unit costs for treated water would be reducedin these applications.

SUMMARY

One aspect of the current invention is an EMC/F wastewater treatmentsystem incorporating a number of specific technologies that whenemployed collectively in series treats and removes contaminants from abroad spectrum of wastewaters. More specifically, the current inventioncomprises a mobile or portable water treatment process for reaction,capturing and removing total suspended solids, carbon dioxide, hydrogensulfide, volatile organic compounds, non-volatile organic compounds,oxides and hydroxides of heavy metals, metal carbonates, dissolvedsolids, petroleum products or a mixture thereof from frac flowback orproduced water. The system treatment process comprises a first pumpingof the frac flowback or produced water through a pair of filters havinginlets that are hydraulically connected to a source of frac or producedwater, wherein said filters capture macroscopic debris for disposal. Asecond step of pumping flowback water from filters through an outlethaving connection to a pair of flowlines with probes inserted into thesaid flowlines to monitor temperature, pH, flow and conductivity; andpumping the flowback water through a set of flowlines in hydrauliccommunication with a magnetic field produced by an around-the-pipeelectromagnet or permanent magnet to form first reaction products ofcalcium carbonate crystals, aragonite produced from calcium carbonatecrystals, calcite; pumping the flowbackwater through a divided secondflowline with each division line in hydraulic connection to one of twomechanical hydrocavitation devices to initiate second reaction productsfrom production of free radicals, including those of oxygen, hydrogen,nitrogen and carbon, initiating bicarbonate to carbonate shift resultingin the formation of insoluble calcium carbonate and magnesium carbonate,and the stripping of gases of hydrogen sulfide, carbon dioxide andvolatile organic carbon compounds from the treated water. A third stepof pumping the flowback water through a third flowline in fluidconnection to a horizontal surge separation tank for the formation ofoxides of metals and metal hydroxides, venting of gases to atmosphere,discharge of solids to drain and for equilibration of water pressure toatmospheric pressure. A fourth step of flowing the flowback water fromthe horizontal surge separation tank outlet into a fourth flowline, withsaid flowline dividing and each in hydraulic communication with one oftwo electrocoagulation devices to initiate the formation of fourthreaction products of electrochemically produced ferrous hydroxide andferric hydroxide, which act as flocculants to remove reactive andnon-reactive cations and anions, organic compounds, heavy metals and oiland grease and volatile organic compounds and to generate gases ofhydrogen and chlorine and the hypochlorite anion. A fifth step ofpumping the flowback water into a fifth flowline that is fluidcommunication with a horizontal atmospheric buffer tank which allowsseparation of gases and venting thereof to the atmosphere and separationof heavier formed solids for discharge to drain line. Subprocessesinclude flowing the water from horizontal atmospheric separation tankinto a sixth flowline which is in fluid communication with one of twopumps; pumping flowback water via a seventh flowline which is in fluidcommunication with a hydrocyclone, which separates larger formed solidsfrom the flowback water with said formed solids discharging to ahorizontal drain tank while the water from the hydrocyclone isdischarged into an eighth flowline, equipped with probes to monitor pH,flow and conductivity and, discharging flowback water to aflocculation/sedimentation tank (frac or frack tank) which will separateremainder of formed solids from said flowback water and removing saidflowback water from the flocculation/sedimentation tank for recycle inwell fracing operations.

BRIEF DESCRIPTION OF DRAWINGS

The following drawings form part of the present specification and areincluded to further demonstrate certain aspects of the presentinvention. The invention may be better understood by reference to one ormore of these drawings in combination with the detailed description ofspecific embodiments presented herein.

FIG. 1A-1B shows Process and Instrumentation Diagrams for the EMC/FSystem and illustrates three sections of the EMC/F System and the layoutof the System on an approximate 40 ft. skid, wherein the electricalsupply is provided by a power source located outside the System.

FIG. 2 shows a Plan View and layout of the EMC/F System.

FIG. 3 shows an Elevation View and layout of the EMC/F System.

FIG. 4 shows an End View and layout of the EMC/F System.

FIG. 5 shows a diagrammatic illustration of effect of magnetic forcefield on calcium carbonate nucleation and crystallization in flowingwater.

FIG. 6 shows Table 1 representing treatment testing results for fracflowback water from a Barnett Shale gas well. These data show theefficacy of treatment and removal of contaminant species from fracflowback water.

FIG. 7 shows Table 2 representing results from EMC/F biocidal treatmentof frac flowback water. These data demonstrate the efficacy of EMC/F asa biocidal treatment for frac source and frac flowback water.

FIG. 8 shows Table 3 representing EMC/F efficacy for treatability ofvarious chemical constituents commonly found in wastewater.

DETAILED DESCRIPTION

Terms: Before describing the present invention in detail, it is to beunderstood that this invention is not limited to particular apparatus,machines, compositions or composition delivery systems, which may vary.One having ordinary skill in the art will understand that theterminology used herein is for the purpose of describing particularembodiments only, and is not intended to be limiting. In addition,before describing detailed embodiments of the invention, it will beuseful to set forth definitions that are used in describing theinvention. The definitions set forth apply only to the terms as they areused in this patent and may not be applicable to the same terms as usedelsewhere, for example in scientific literature or other patents orapplications including other applications by these inventors or assignedto common owners. Additionally, when examples are given, they areintended to be exemplary only and not to be restrictive.

It must be noted that, as used in this specification and the appendedclaims, the singular forms “a,” “an” and “the” include plural referentsunless the context clearly dictates otherwise. Thus, for example,reference to “an electrolytic treatment apparatus” includes a system oftwo or more such machines, reference to “a base” includes mixtures oftwo or more bases, reference to “an acid” includes mixtures of two ormore acids, and the like.

In describing and claiming the present invention, the followingterminology will be used in accordance with the definitions set outbelow.

The terms “wastewater,” “contaminated water” and “Pollutants,” aretypically used interchangeably herein to refer to water that is harmfulfor human consumption. The terms also encompass chemically acceptable,chemically active derivatives and analogs of such compositions,including, but not limited to: surface water contaminated with untreatedhuman waste, animal waste, water born disease organisms, heavy metalsorganic products, petroleum, salts, esters, amides, active metabolites,inclusion complexes, analogs, and the like.

The term “Electrocoagulation” or “electroflocculation” as used hereinare interchangeable and terms used to describe the utilization ofelectrical energy to cause the flocculation of dissolved and suspendedcontaminants from an aqueous medium.

The term “Hydrocavitation” or “cavitation” as used herein are themechanically induced formation of vapor or gas filled bubbles in aliquid when tensile stress is superimposed on ambient pressure. Suchbubbles upon collapse may reach temperatures of several thousand degreesFahrenheit, sufficient to force dissolved gases from solution, catalyzethe formation of free radicals and breaking of chemical bonds. Suchviolent treatment action of cavitation will kill most biologicalorganisms within the water. Cavitation, therefore, serves as a form ofbiocidal treatment.

The term “Biocide treatment” as used herein, refers most often to atreatment performed with a variety of toxic chemicals being employed inpathogen reduction and is used to eliminate biological organisms(including pathogens and algae) from water. Pathogens would includeorganisms of bacteria, fungi, various worms, larvae or eggs and viruses.

Introduction to the EMC/F System. Many wastewater contaminants are heldin solution due primarily to prevailing negative electrical charges onthe contaminants. Bacteria, algae, oils, clays, carbon black, silica,phosphate, nickel, lead, chromate and other ions, are some examples.Neutralization of these charges and the subsequent precipitation ofthese contaminants can be achieved either by chemical or byelectrochemical means. Electrocoagulation systems have been employed foryears in the treatment of wastewater. Most rely upon high currentdensity to produce a strong electrical field in order to disrupt theattraction of the particles, allowing suspended contaminants toco-precipitate with metal ions sacrificed or produced from systemelectrodes.

In the past, these systems have shown good contaminant removal comparedto chemical precipitation, nevertheless, higher capital and operationcosts, along with lower flow rates, have prevented widespread adoptionof these systems. In today's regulatory and business environment,chemical treatment is becoming less acceptable due to more stringentregulations and increased chemical and sludge disposal costs. Solidresidues may be classified as hazardous and treatment levels are moredifficult to achieve. Lower operating costs, higher flow rates andbetter knowledge of the process have elevated ELECTROCOAGULATION to thetreatment process of choice for many different wastewaters.

EMC/F SYSTEM consists of a group of devices and equipment that, whenarranged and applied collectively as a process, take advantage of aselection of individual technology attributes to form an advancedtechnology system based on principles of physico-chemistry, includingcavitation, electromagnetics, electrochemistry and hydrocyclonics, asshown in FIG. 1A to FIG. 4.

These advances are made possible by modern electronics. EMC/F SYSTEMcombines these technologies and principles into a practical, compact,easy to use device. The EMC/F system's unique design effects treatmentof aqueous solutions that are contaminated with a variety of materialsincluding heavy metals, oil, grease, suspended solids, some salts anddissolved solids, as well as, bacteria, fungi and algae.

The combined cavitational, magnetic, electrochemical and hydrocycloneprocesses impart increased pressure and temperature changes and chemicaland electrical charge changes to the waste fluid. These physical changesand electrical charges destabilize the waste fluid, causing thecoagulation of many of the dissolved and suspended materials present.Destabilization is the result of the suppression of zeta forces thatkeep components in the water matrix dispersed. Contaminants are free toassociate and coalesce or migrate to areas of high energy near theelectrode surfaces. The energized components can then interact withother contaminants, particularly those of free radicals and hydrolyzedwater molecules or free electrons flowing through the system. The resultis a chemically altered, less soluble product capable of separation fromthe water.

The EMC/F SYSTEM utilizes a proprietary system that applies acavitational force field (cavitation unit), a magnetic force field,electrochemical energy (EC unit) and hydrocylone unit to a flowingaqueous waste stream. Contaminant-laden water moves sequentially throughthese individual units where treatment is accomplished by the action andinteraction of four basic processes:

IONIZATION. Ionization occurs due to the strong attractive forces of theanode and cathode. Alkali metals and halogens are most notably affected.Certain alkaline earths and transition metals will also readily ionizein a strong electric field. The reaction of these atoms results inseparation from the water matrix and migration to one of the electrodes.In addition, significant bond stretch and subsequent weakening of thecovalent forces that hold the molecule together may occur. Weakenedbonds are sites for attack by other atoms or species in solution,particularly those of free radicals and oxidants. Regardless of thesubsequent interactions between the contaminants, the electrodes, and orthe water, ionization effects cause the destabilization of the solutionand result in the formation of new compounds inside the cell and afterleaving the treatment cell.

ELECTROLYSIS. Electrolysis results in the pulling apart of moleculesinto their elements, e.g., water into hydrogen and oxygen gasses. Oftenthis action is much more aggressive than ionization and results inground state atoms. Both organic and inorganic molecules are susceptibleto electrolysis in the EC cells. Organic molecules generally requiremore energy input than inorganics. The hydrolysis of water producesintermediates that are effective in reacting with ionized atoms orattacking the stretched bonds.

Free Radical Formation. Oxygen, Nitrogen, Hydrogen, Carbon, and otherelements respond to electromagnetic currents and cavitation to form freeradicals. These unstable highly energized atoms are responsible forextremely aggressive compound and complex formation. The occurrence offree radicals is not common in natural waters due to the unusual energyrequirements necessary to create the excited state. Free radicals mayalso attack certain bonds to cause the decomposition of some molecules,substitution and add-on reactions and denaturization of proteins.

Electromagnetic Fields. Electromagnetic fields have long been known toaffect the electrons in atoms. The very basis of our understanding ofatomic structure and chemical reactions was developed from anunderstanding of electromagnetic fields. The shifts in electron positionor energy as a response to the electromagnetism will destabilizecompounds and complexes within the aqueous medium. Destabilization leadsto dissociations and alteration of the chemical equilibria in the water.Under the influence of the magnetic fields, crystalline structures maybe altered (e.g. calcium carbonate) in the waste stream and areprecipitated in a form that does not readily form scale (aragonite).This reaction would be of considerable importance in frac water flowbacktreatment and reuse since it would result in water with reduced downholescaling potential.

Flocculation and coagulation are common to most water treatment systems.Chemical treatments generally require two or more additives and aresensitive to timing and mixing. EMC/F System incorporates an electriccurrent in order to neutralize ionic and particulate charges therebyallowing contaminants such as colloidal particulates, oils and dissolvedmetals to coalesce and be removed from stable suspensions and emulsions.The principles of consideration are double layer dynamics, chargeneutralization, bridging/entrapment and increased particle size. Theeffects are caused by the four basic processes interacting with themolecular suspended or colloidal particles dispersed in the watermatrix.

Chemical reactions aid in the purification of water and aretraditionally accomplished by addition of chemicals, control of pH,temperature, biological activities, or some form of external energyaddition. EMC/F system accomplishes the same chemical reactions usingelectrical and cavitational energy applied at the electrode interfaceand throughout the solution in the treatment unit. Ion formation, freeradical formation, dissociation, hydrolysis, crystal formation andcatalyzed complex formation are just a few of the processes that areinitiated by the carefully controlled application of electrical energyin EMC/F system. Inorganic minerals and compounds are most profoundlyaffected by these processes and are chemically altered into less solublespecies. Organics may also be affected through the changes in atomicbonds through add-on and substitution reactions mediated by theelectrical field and free radicals. Certain bonds are more susceptibleto attack by the free radicals in the energized aqueous medium which mayresult in less complex and more readily processed components.

The EMC/F technology components were collectively developed andevaluated over a significant period of research and development time inan effort to minimize and optimize a large number of independent andinterdependent variables associated with energy transfer, waterchemistry and the phenomena described above. Each parameter wasevaluated independently to determine the range of effect on certainchemical components of frac flowback water. This parameter informationwas individually optimized and finally incorporated into a complexsystem to evaluate energy transfer that would allow EMC/F to operate andtreat wastewater most effectively.

The result of these efforts is an optimized process design.Understanding of the importance and the effect on treatment of eachparameter allows for the standardization of critical elements in thetreatment process design and the ability to adjust the remainder to thecomponents associated with the waste stream.

EC Treatment cells for electrocoagulation systems consist of sacrificialelectrodes that provide much of the treatment chemistry. Examples oftypical reactions within a treatment cell include:

Anode: Fe⁰→Fe⁺²+2(OH⁻¹)→Fe(OH)₂+Fe⁺³+3OH⁻¹→Fe(OH)_(3 (insoluble))

Ca⁺²+2OH⁻¹→Ca(OH)_(2 (insoluble))

Cathode: 2H₂O→2H₂+O₂

2 H⁺→H₂

2 Cl⁻¹→Cl₂

Ferric hydroxide is insoluble and serves as the internally generatedflocculant. In addition, the hydroxides of other divalent cations ofcalcium and magnesium, including those of the heavy metals, react withthe hydroxide to form insoluble precipitates. Examples of treatment testdata for frac flowback wastewater are given in Table 1 in FIG. 6.

The number of cells in use is determined by flow demand. Cells can treat40 to 250 gallons or more per minute depending on the wastewatertreatment volume needs.

Maintenance and Operation—Each cell is continuously monitored forvoltage, current, water flow, conductivity and temperature by systemunits within the control panel. These are the basic parameters affectingtreatment of the contaminated water. Many of the system functions can beautomated to reduce personnel time. Data will be logged and will beretrievable from a dedicated computing device. In addition, SCADAtechnology incorporation, will allow off-site monitoring of operation.

Electrical power usage is controlled by the contaminant load within thewater being treated. Less power is required when the contamination levelis high (high TDS) whereas, more power is required when the contaminantlevel is low (low TDS). This provides an efficient utilization of theenergy required by the system resulting in little wasted energy.

Cavitation treatment—Cavitation treatment consists of passing thewastewater through a specially designed cavitation cell with the pump ata Total Dynamic Head (TDH) of 100 to 300 ft and more specifically of 208ft. and providing a cavitation chamber pressure of 50 psi to 200 psi andmore specifically, 90 psi to 120 psi. The ranges are not meant to belimiting but are given as examples of a useful operating range employedherein. Those actions and reactions occurring within the cavitationdevice include:

-   -   Pressure induced physical destruction of biological organisms        (see Table 2 in FIG. 7 in Drawings and Tables Section).    -   Dissolved gases, such carbon dioxide, hydrogen sulfide, and        volatile organics are stripped from the liquid.    -   Physico-chemical reaction kinetics leading to free radical        formation and subsequent oxidation reactions within the waste        stream.    -   Chemical reactions induced by cavitation which facilitate the        production of the insoluble carbonates of divalent cations,        including calcium and magnesium.

Magnetic treatment—Magnetic treatment of water has been shown to affectthe nucleation and crystallization of calcium and magnesium carbonates.Subjecting flowing water to a specific magnetic force field can alterthe predominant crystal form of calcium carbonate calcite crystal toaragonite crystal and enhance the nucleation of the crystal (see FIG.2). The aragonite does not form a hard calcium carbonate scale as doescalcite; aragonite tends to remain non-adherent, soft and feathery orpowdery. This type of crystal tends to remain suspended in the fluid butflocs readily form.

Another important effect is on the aggregates of water molecules. Undernormal conditions, water molecules are thought to be locked inaggregates in liquid water with less than 20% occurring as free watermolecules. The aggregated form is thought to be due to the fact thatwater has a dipole moment—the hydrogen atom is attracted to the oxygenatom of the adjacent molecule. The magnetic field produces molecularagitation whose frequency is tuned to the natural frequency of watermolecules vibrating in the aggregates. Through the cooperative resonanceof the water molecules, free water molecules become available throughbreaking of the hydrogen bonds. This can result in decreased viscosity(reduced surface tension) and an increase of solutioning power of waterand more readily dissolve scales and other species and reduce corrosionof piping. Such magnetic treatment of waterflood in tertiary oilproduction has been shown to decrease formation pressure necessary forwater drive and to increase oil production. In addition to its role inwastewater treatment, magnetically treated water will provide theadditional benefit of reducing the potential for downhole-scaling andcorrosion of pipe associated with drilling, fracing and productionactivities in the oil and gas industry. For example, FIG. 5 shows adiagrammatic illustration of effect of magnetic force field on calciumcarbonate nucleation and crystallization in flowing water

Major Advantages of EMC/F System. Advantages of the EMC/F over othertreatment systems are:

-   -   Removal of a broad range of both, organic and inorganic        contaminants (see Table 1 in FIG. 6 of Drawings Section).    -   Toxic heavy metals in their insoluble hydroxide forms do not        tend to leach, i.e., solids pass the EPA's TCLP test.    -   A high degree of contaminant removal is achieved, facilitating        reuse of the treated water.    -   Floc tends to be stable and settles rapidly.    -   Maintenance and operation are simple.    -   Odor reduction or elimination due to cavitation pressure-induced        evolution of noxious gases and the oxidation reactions (e.g.,        sulfides).    -   Small “footprint”.    -   Growth easy to accommodate; due to modular design, additional        units may be added to facilitate increased treatment needs.    -   Bacterial destruction (to non-detection levels) through        cavitation pressure and the production of free radicals and        disinfectants, including chlorination products and hydrogen        peroxide (see Table 2 in FIG. 7 of Drawings Section).    -   Divalent cations(known to produce scaling) and heavy metals        removal through production of their insoluble hydroxides and        carbonates.    -   Crystal form of calcium carbonate is converted to aragonite form        which is non-scale forming.    -   An optional programmable logic controller (PLC) providing for        efficient operation.    -   Cost efficient when compared to other options.    -   Mobile operation with components located on a single skid.

The main features of the EMC/F System are as follows:

-   -   The System is user friendly, requiring minimal supervision.    -   Design and manufacturing costs are low when compared to        competitive units of similar capacity and water quality.    -   Flow meters are added to provide accurate measurements of the        liquid being delivered to the system, processed, or discharged        as treated materials.    -   Ampere and voltage metering is displayed indicating the amps and        volts being supplied to each treatment cell within the unit.    -   Individual treatment cells are easily replaced without the need        for unit shutdown.

An optional programmable logic controller (“PLC”) provides back pressuresafeguards alerting to the blockage or unexpected wear on the EMC/Fsystem and providing for automatic shut down in the event of failure ofany part of the system. In addition, process variables of flow rate andpower can be optimized and quality parameters of pH, TDS, andconductivity can be continuously monitored.

EXAMPLES

The following examples are provided to further illustrate this inventionand the manner in which it may be carried out. It will be understood byone of ordinary skill in the art, however, that the specific detailsgiven in the examples have been chosen for purposes of illustration onlyand not be construed as limiting the invention.

Example 1

One aspect of the current invention is an EMC/F wastewater treatmentsystem incorporating a number of specific technologies that whenemployed collectively in series treats and removes contaminants from abroad spectrum of wastewaters. The system includes the followingcomponents arranged in series: a hydrocavitation unit, anelectromagnetic unit, an electrocoagulation unit and a hydrocyclone unitand/or a flocculation-sedimentation tank. The system has been designedto optimize process variables via an optionable programmable logiccontroller (“PLC”) in order to effectively transfer hydrodynamic,electrical and electromagnetic energy to the continuously flowingcontaminated waste water. Water-contaminant mixtures treated by an EMC/Fsystem will separate into an organic floating layer, a mineral-richsediment layer and a clean water layer in the middle. This separationoccurs within minutes of treatment and conventional equipment(flocculation-sedimentation tank and filtering, if needed) may be usedto extract the clean water for reuse or discharge.

The invention is a multi-component device that can be applied to a broadspectrum of water and wastewater treatment requirements. The technologyis most applicable to separation of inorganic contaminants, biologicalcontaminants, and <2% petroleum hydrocarbons. EMC/F is not appropriatefor solvents, sludge, complex amines, sugars or alcohols as a standalonetreatment system. In combination with other technologies, such as RO fordesalination, the system may be employed to produce significantly higherquality water for reuse or discharge. The EMC/F system also lends itselfto treatment of complex mixed wastewater streams and as a pretreatmentto increase efficiency of other purification and desalination systems.

The system has been successfully operated in a number of differentapplications. Treatment of shale gas frac water flowback for reuse andplating plant wastewaters have been treated successfully. As shown inTable 1 of FIG. 7, reductions in divalent cations, some salts, heavymetals, oil and grease, BTEX, TSS, TDS, sulfides, and sulfates werehighly significant. The particular wastewaters treated here are notexclusive to those industries cited but only serve as examples.Treatment may be extended to include other industrial wastewaters aswould be recognized by anyone schooled in the art.

Bacterial reduction or preferably complete elimination from water foruse or reuse in drilling operations is highly desirable since bacteria,entering downhole formations with water for drilling or hydraulicfracing can reproduce within the formation and result in fouling ofwells. This is particularly true for Acid Producing Bacteria (“APB”) andSulfur Reducing Bacteria (“SRB”). The EMC/F technology is a “GreenTechnology”. It destroys bacterial organisms through physical,electrical and free radical actions. It will benefit drilling andfracing operations by reducing the need for use of toxic biocidalchemicals used by the oil and gas industry and currently the subject ofconsiderable concern and controversy relating to potential contaminationof potable groundwater aquifers and contamination of surface suppliesdue to surface spills.

EMC/F system is a chemical-free technology that relies onelectro-mechanical action for treatment to achieve a Non-detect level(below detection limit, see Table 2 in FIG. 7) of bacterial organismsencountered in source water for drilling and fracing and for treatmentof frac flowback wastewater for reuse.

Treatability studies have been performed on a number of differentwaste-waters. The EMC/F system has demonstrated efficacy in treatment ofa broad spectrum of chemical and physical contaminants as shown in Table3 in FIG. 8.

Many varying and different embodiments may be made within the scope ofthe inventive concept herein taught, and because many modifications maybe made in the embodiments herein detailed in accordance with thedescriptive requirements of the law, it is understood that the detailsherein are to be interpreted as illustrative and not in any senselimiting.

The EMC/F System is portable and designed for field use. The system isnot, however limited to portable field use but may also be placed on afixed site.

The EMC/F System is novel and comprised of four separate water treatmenttechnologies, including 1) hydrocavitation unit, 2) electromagneticunit, 3) electrocoagulation unit and 4) hydrocyclone unit, all connectedin series with each unit performing a different treatment task.

Arrangement of the individual treatment technologies in series may bevaried in order to accomplish different treatment needs and all suchpossible arrangements and sequences are claimed. This characteristicaccomplishes what other systems lack, adaptability as discussed above.

The EMC/F System is modular and mounted on a 40 ft. skid for ease ofloading and unloading at a site.

The EMC/F System is a dynamic flow-through system and has a volumethroughput of up to 250 gallons per minute and is large when compared toother portable industrial wastewater treatment systems.

The EMC/F System as described is modular in design and can accommodatelarger treatment volumes by adding additional modules, thus increasingadaptability.

The EMC/F System as described allows for repetitive cycling of water inthe treatment process, thus increasing treatment efficiency.

The EMC/F is a “Green Technology” which in this sense asserts that thesystem does not require the addition of chemicals to operate properly inthe treatment of wastewater for purposes of reuse or discharge.

As a result of the fact that this is a green technology, there are nohazardous wastes generated in the process and no toxic waste requiringdisposal.

The EMC/F System operation, as well as individual unit operation, may beoptimized by an optional programmable logic controller (“PLC”) toprovide back pressure safeguards alerting to blockage or unexpected wearon the EMC/F System components, thus providing for automatic shut downin the event of failure of any part of the system. In addition, processvariables of flow rate and power can be optimized and continuouslymonitored. This feature allows for increased efficiency of systemoperation and lower treatment costs.

Example 2

Turning now to FIG. 1A, power to all system components is regulatedthrough a Central Control Panel (9). Water is pumped from a waterholding tank (10) at 40 to 250 gpm and enters the treatment systemtrain. The water passes through a flexible flowline (11) with a shutoffvalve (21) and through one of two 1/32 in. in-line screen filters (13)to remove larger debris. The filters are equipped with one-half in. ballvalves (14 and 18) which are connected to a drain line (39) fordischarge of accumulated debris which passes through the filter.

The water then passes from the filters through the flowline where theflowline pressure is monitored by a pressure gauge (15). The waterenters one of two centrifugal pumps (16) equipped with monitoring gaugesfor flow (17) and (17B). Upon exit from the pumps, the flowline changesin diameter from 3 in. to 4 in. (19), past a check valve (20) and a 4in. ball valve (21). The pumps are equipped with a one-half in. ballvalves (18) for discharge of accumulated debris that is also connectedto drain line (39). The water then flows past probes that are insertedto monitor temperature (22), pH (23), flow (24) and (25), andconductivity (26) of the water. The monitoring gauges for the probes areshown as (22B), (23B), (25B) and (26B), respectively.

From this point the flowline is reduced in diameter by (19) from 4 in.to 3 in. The water flows through an electromagnetic field provided by anaround-the-pipe 4 in. by 36 in. electromagnetic conditioning tube (28),located on a dielectric insert section of the pipe. The force field isestablished at 2500 to 7000 gauss and regulated by (27) at the centerpoint of the insert-pipe. This magnetic force field has been determinedto have the maximum direct effect on calcium carbonate crystal formwithin the flowing water. The predominant crystal form shifts fromcalcite to aragonite under the force field stated above, which inaragonite form is resistant to scaling. This reduces scaling andbuild-up of calcium carbonate on the electrodes within the EC Unit andin turn, reduces maintenance time and costs associated with electrodetreatment or replacement. In addition, downhole scaling potential of thewater is reduced upon reuse in fracing. The flowline diameter isincreased to 4 in. (19) after passing the electromagnetic device. Theflow pressure is adjusted to 150 psi by the in-line pressure regulator(29).

The water is then pumped into one of two in-line 3 in. by 6 in. chamberhydrocavitation units (35), as described by Kelsey et. al. U.S. Pat. No.7,651,614, at a total pressure of 175 psi. Prior to entry, the dividedflowlines are equipped with 4 in. shutoff valves (21) for use in serviceof the hydrocavitation units. This allows either unit to be isolated forservice. Both units are open during not mal operation. Upon entry intothe hydrocavitation unit, the water divides into two streams. Thestreams are forced through opposing eductors, colliding midway betweenthe two. The cavitation chamber pressure is fixed at 90 psi andmonitored by (36), (38) and (38B). The units are provided with one-halfin. drains (18) to discharge solids into the drain line (39). Uponcollision of the two streams, very small bubbles form and implode underthe formation of a vacuum created in the chamber. Implosion of thebubbles liberates significant energy in the form of heat (estimates havebeen made that such imploding bubbles may reach temperatures as high as90000F). Such violent collision and high temperatures will destroy mostbiological organisms within 2 radii of the bubble and force dissolvedgases from the water stream, including carbon dioxide, hydrogen sulfide,and volatile organics. In the case of carbon dioxide evolution from thebulk liquid, a pH shift to alkaline follows. This shift is due to thebicarbonate-carbonate equilibrium shift to carbonate. The carbonate ionsreact with calcium and magnesium ions to form the respective carbonatesand, if solubility constants are exceeded, precipitation of calciumcarbonate and magnesium carbonate ensues. This precipitate is removedduring later stages of treatment. Implosions can catalyze other chemicalreactions and create energetic free radicals, hydrogen peroxide andhypochlorite ion which in turn, react with other chemical species tobreak chemical bonds and alter organic and inorganic species within thebulk liquid. These reactions serve to destabilize colloids and reducethe zeta potential of the liquid. Destabilization and zeta potentialreduction are necessary for later flocculation and sedimentation ofinsoluble contaminants. Any precipitated solids which do form in thissection are discharged to drain line (39) as discussed below.

Water from the hydrocavitation units passes a pressure regulator (34)which reduces the pressure to 25 psi. The water then enters an elevated36 in. diameter by 72 in. long horizontal surge separation tank (33).This accomplishes two things: (1) evolved gases of hydrogen, carbondioxide and other gases are vented from this tank to vent lines (58)which discharge to the atmosphere and (2) the necessary hydraulic headfor feed water to the next section of the system is obtained. Tankpressure and water level are monitored by instrumentation (31) and (32).Water from (33) flows by way of (35B) to one of two ElectrocoagulationUnits FIG. 1B (43) as described below. Sediment and formed solids fromthe tank are discharged via (36) to the drain line (39).

FIG. 1B illustrates the path of water entering the next section of thetreatment train. The entering water stream (35B) divides into twostreams flowing at 125 gpm each as regulated by 2 in. ball valves (36).These valves also allow the reactors to be isolated for maintenancepurposes and flow to bypass the reactors. Each of the two streams flowsinto one of two Electrocoagulation Reactors (43), as described byHermann et al. in U.S. Pat. No. 6,780,292. Flow to and from each reactoris via flowlines (35B). Power level is adjusted by control switch (40)and water temperature is monitored by instrumentation (41). Electricalpower is supplied to each reactor from off-skid power rated for 150 ampsat 220 volts (45) each. The water flows between iron anodes and cathodeswithin the reactors. In doing so, iron in the form of ferrous and ferricions is produced from the anodes. These ions react with hydroxyl ions,also produced within the water. These ions react to form insolubleprecipitates of ferrous and ferric hydroxide. Additional reactions occurto form other insoluble species, including hydroxides of various cationsand those of heavy metals. Cathodic reactions include the production ofhydrogen and chlorine gases. A portion of the chlorine gas may ionize toform the hypochlorite ion which serves as a disinfectant. Free gasesfrom the cathodic reaction are vented to the atmosphere via vent line(59). Insoluble precipitates from the system are routed to drain line(39). Upon leaving the reactors, the water passes 4 in. butterfly valves(42) which prevent backflow to the reactors and passes to the flowline(35B). The water then enters a 35 in. diameter by 84 in. long horizontalatmospheric buffer tank (44). Tank pressure and water level aremonitored via instrumentation (31) and (32). This tank is vented to theatmosphere via vent line (58). Accumulated solids within this tank aredischarged to drain line (39). The treated water is pumped from theholding tank via 6 in. flowline (35B). Inserted into the line is apressure gauge (15) to monitor pressure within the line. The water thenflows to a downstream point where the flowline is divided onto twostreams by 4 in. flowlines. Each flowline has a 4 in. ball valveinserted to allow flow or shut off flow to each of two spared ANSICentrifugal Pumps, rated at 1800 rpm and 250 gpm (46). The redundancy ofpumps allows service to one or the other in case one pump fails.Associated pump components (47), (47B), (18), (19), (20) and (21) arethe same as previously described above. Water flows from the pumps byflowlines (35B) and passes to the separator section, FIG. 1C

FIG. 1C illustrates the separator section of the treatment train. Wateris pumped from the previous section, via line 35 and enters a 24 in. by36 in. hydro-cyclone type separator Unit (49). The hydrocyclone functionis to remove any large accumulation of heavy precipitate that haspreviously formed as a result of electrocoagulation treatment. Thesolids are discharged through a 3 in. valve (50) located on the bottomof the hydrocyclone. The valve is self-actuating (52) as a function ofconductivity and pressure metering by (26) and (26B), respectively. Inaddition, aeration of the water by the hydrocyclone facilitates theoxidation of any remaining ferrous ion to ferric ion, which is lesssoluble. Insoluble solids which fall out of solution are discharged to a24 in. diameter by 48 in long horizontal holding tank (51). Pressure andtank fluid level are monitored by (30), (31) and (32). The drainage fromthis tank enters the flowline (57) for discharge. Pumps (54), withassociated monitoring instrumentation (55) and (55B) and associated flowcontrols (18), (20), and (56), move the sludge to the discharge flowline(61). Drainage from the flowline (57) and drainage from the skid (61)are collected into a tank for off-site disposal. The treated water ispumped into the cleaner water flowline (35B) and passes inlinemonitoring probes for temperature, flow, and conductivity (23), (23B),(24), (25), (25B), (26) and (26B). The cleaner water discharges via(35B) and (11) into a three-section, 500 barrel flocculation/sedimentformation tank (60). The water is treated by conventional flocculationand sedimentations methods in this tank. The water first enters theseparation section where much of the settleable solids flocculate andprecipitate out of the water. The water then flows into the next sectionwhich contains settling tubes, which facilitate the precipitation offiner settleable solids. The water flows from the second section intothe final section for polishing. Upon completion of movement through thetank, the clean water is removed and stored or reused in fracingoperations. If necessary or required, the water may be filtered afterpassing through the flocculation-sedimentation tank. Additionally, thewater may be treated by reverse osmosis to further reduce dissolvedsolids.

Settleable solids which accumulate as tank bottoms are periodicallyremoved by pneumatic tanker truck and disposed off-site.

The EMC/F Wastewater Treatment System, as described herein, can beemployed to treat frac water but additionally, can be used to treatproduced water from oil and gas drilling industry, as well as, otherindustrial wastewaters.

FIG. 2 represents the Plan View of the complete EMC/F Unit mounted on askid. The skid dimensions are 40 ft. (length)×11.5 ft (height)×8.5 ft(width). Water enters the system at the 4 in. inlet and passes throughone of two pumps (16). Then the water passes through the magnetic fieldand into one of two cavitation devices (not shown in this view). Fromthe cavitation devices, the water is pumped (16) into the horizontalsurge tank (33). The water then flows via flowline (35B) into one of twoElectrocoagulation cells (43). Device 44 is a horizontal atmosphericbuffer tank which collects gases from the EC cells for discharge to theatmosphere and also serves as a tank for the treated water. The waterflows from this tank to one of two duplicate pumps (46) which pumps thewater to the hydrocavitation Unit (49). Sediment and precipitatedischarge into tank (51) which discharges to sludge drain. Water ispumped (54) from the system via the 4 in. outlet drain line (11) andpasses to the Frac Tank (60) for flocculation/sedimentation. The ControlRoom is shown in (63) with the Lab Desk (62) and Control Panel (9)located within.

FIG. 3 represents the Elevation View of the complete EMC/F Unit on theskid. All component numbers are as given previously in the abovefigures, with the exception of (64) which is the atmospheric dischargeline for gases generated within the treatment system.

FIG. 4 represents the End View of the complete EMC/F Unit on the skid.All component numbers are as given previously in the above figures.

Table 1 in FIG. 6, represents treatment testing results for fracflowback water from a Barnett Shale gas well. These data show theefficacy of treatment and removal of contaminant species from fracflowback water.

Table 2 in FIG. 7 in FIG. 8, represents results from EMC/F biocidaltreatment of frac flowback water. These data demonstrate the efficacy ofEMC/F as a biocidal treatment for frac source and frac flowback water.

Table 3 in FIG. 8 represents EMC/F efficacy for treatability of variouschemical constituents commonly found in wastewater.

REFERENCES

U.S. Pat. No. 7,651,614 issued on Jan. 26, 2010, titled “Methods fortreatment of wastewater,” having Kelsey, et al., listed as inventors.

U.S. Pat. No. 6,780,292 issued on Aug. 24, 2004, titled “Electrolytictreatment apparatus having replaceable and interchangeable electrodereactor cartridges therefore”, having Hermann, et al., listed asinventor.

The Future of Water, Discover Science, Technology and the Future, pp.50-53, December 2011.

1-17. (canceled)
 18. A mobile or portable water treatment process for capturing and removing suspended and dissolved solids, carbon dioxide, hydrogen sulfide, volatile and non-volatile organic compounds, oxides and hydroxides of heavy metals, metal carbonates, petroleum products, or a mixture thereof from a frac flowback or produced water, the process comprising: a) pumping the frac flowback or produced water through a pair of filters having a plurality of inlets, the inlets being hydraulically connected to a source of the frac flowback or produced water, wherein the filters capture macroscopic debris for disposal giving a filtered flowback or produced water; b) pumping the filtered flowback or produced water from the pair of filters through an outlet having a connection to a pair of first flowlines with probes inserted into the flowlines to monitor temperature, pH, flow, and conductivity; c) pumping the filtered flowback or produced water through the pair of first flowlines, wherein the pair of first flowlines is in hydraulic communication with a magnetic field produced by an around-the-pipe electromagnet, or by a permanent magnet, to give a second flowback or produced water; d) pumping the second flowback or produced water through a divided second flowline having two or more divided lines wherein each divided line is in hydraulic connection to one of two mechanical hydrocavitation devices to produce a treated second flowback or produced water; e) pumping the treated second flowback or produced water through a third flowline in fluid connection to a horizontal surge separation tank having a horizontal surge separation tank outlet to give a third flowback or produced water; f) flowing the third flowback or produced water from the horizontal surge separation tank outlet into a fourth flowline, wherein the fourth flowline has two or more divided lines and each divided line is in hydraulic communication with one of two electrocoagulation devices to give a fourth flowback or produced water; g) pumping the fourth flowback or produced water into a fifth flowline which is in fluid communication with a horizontal atmospheric separation tank to give a fifth flowback or produced water; h) flowing the fifth flowback or produced water from the horizontal atmospheric separation tank into a sixth flowline to give a sixth flowback or produced water, wherein the sixth flowline is in fluid communication with one of two pumps; i) pumping the sixth flowback or produced water via a seventh flowline to give a seventh flowback or produced water, wherein the seventh flowline is in fluid communication with a hydrocyclone; j) discharging the seventh flowback or produced water via an eighth flowline to a flocculation/sedimentation tank separating any remaining formed solids from the seventh flowback or produced water, wherein said eighth flowline is equipped with means for monitoring pH, flow, and conductivity; and k) removing the seventh flowback or produced water from the flocculation/sedimentation tank for recycle in well fracing operations.
 19. The process of claim 18, wherein the around-the-pipe electromagnet or the permanent magnet of step c) is located around the third flowline and prior to the horizontal surge separation tank.
 20. The process of claim 18, wherein the step of pumping the frac flowback or produced water through a pair of filters of steps a) further comprises pumping the frac flowback or produced water through a hydrocyclone before reaching the pair of filters.
 21. The process of claim 18, wherein the fourth flowline of step f) further comprises a hydrocyclone located before the two or more divided lines.
 22. The process of claim 18, wherein the around-the-pipe electromagnet or the permanent magnet of step c) is in hydraulic communication with at least one of the two mechanical hydrocavitation devices of step d).
 23. The process of claim 18, wherein the around-the-pipe electromagnet or the permanent magnet of step c) is in hydraulic communication with at least one of the two electrocoagulation devices of step f).
 24. The process of claim 18, wherein the around-the-pipe electromagnet or the permanent magnet of step c) is in hydraulic communication with at least one of the two mechanical hydrocavitation devices of step d).
 25. The process of claim 18, wherein at least one of the two mechanical hydrocavitation devices of step d) is in hydraulic communication with at least one of the two electrocoagulation devices of step f).
 26. The process of claim 18, wherein the hydrocyclone of step i) is in hydraulic communication with at least one of the two mechanical hydrocavitation devices of step d).
 27. The process of claim 18, wherein the hydrocyclone of step i) is in hydraulic communication with at least one of the two electrocoagulation devices of step f).
 28. A mobile or portable water treatment system for capturing and removing suspended and dissolved solids, carbon dioxide, hydrogen sulfide, volatile and non-volatile organic compounds, oxides and hydroxides of heavy metals, metal carbonates, petroleum products, or a mixture thereof from a frac flowback or produced water, the system comprising, connected in series: a filtration device; a flocculation/sedimentation device; and a device selected from the group consisting of an electromagnetic device, a hydrocavitation device, an electrocoagulation device, and a combination thereof.
 29. The system of claim 28, wherein the filtration device is located at an inlet, or beginning position of the system and the flocculation/sedimentation device is located at a terminal end of the system. 